Sai Hitesh Bhandaru

Sai Hitesh Bhandaru

Chemical Engineer with 8+ years of experience across semiconductor fabs, petrochemical refineries, and alumina processing plants. Specialized in process optimization, Advanced Process Control (APC), and data-driven modeling using statistical, physics-based, and AI/ML approaches. Proven track record of deploying real-time optimization solutions, leading cross-functional teams, and managing client-facing value realization initiatives.

Work Experience:

8 Years Years

Industry:

Data Science & Analytics, Engineering & Maintenance

Function:

Consulting | Manufacturing & Engineering

Work Experience

Module Development Engineer, Intel Corporation (September 2025 – Present)

1. Developed Advanced Process Control (APC) models and process recipes for Dry Etch modules supporting 14A node development, collaborating closely with layer owners and US-based focus teams.

2. Identified and qualified golden chambers using Special Instruction flags, enabling robust APC model development and standardized recipe creation across tools.

3. Automated fab-level reporting pipelines using SQL Pathfinder and Power BI dashboards, improving visibility into process performance and reducing manual reporting effort.

Data Scientist, Ingenero Technologies (April 2022 – August 2025)

1. Led an 8-member cross-functional team (2 process engineers, 6 data scientists) to deliver real-time plant monitoring and optimization solutions for SABIC’s petrochemical refinery in Saudi Arabia.

2. Delivered 15+ data-driven dashboards for real-time operational monitoring and optimization, enabling faster and more informed decision-making at scale.

3. Developed soft-sensor predictive models and time-series forecasting solutions to estimate catalyst age and performance degradation in live operations.

4. Managed client interactions post-deployment, leading value realization discussions and securing approvals for benefits delivered by deployed models.

Scientist, Aditya Birla Group (July 2019 – March 2022)

1. Developed process optimization advisories using CFD modeling for alumina precipitators and calciners, improving process stability and operational efficiency.

2. Implemented AI/ML-based predictive models in Python for real-time product quality prediction, reducing dependency on frequent laboratory testing.

3. business development initiatives by engaging with unit heads across multiple Hindalco refineries, contributing to acquisition of new optimization projects.

Graduate Apprentice, S&S Technomark Pvt. Ltd (April 2016 – May 2017)

1. Conducted detailed literature surveys and mass & energy balance studies in collaboration with IICT Hyderabad and GACL, Gujarat.

2. Contributed to preparation of Detailed Project Reports (DPRs) and interpretation of PFDs and P&IDs for industrial process studies.
 

Accomplishments

1. Team Titan Award: Recognized for overall team performance and delivery excellence while leading and executing large-scale industrial analytics and optimization projects across multiple client engagements.

2. Best Customer Centricity Award: Awarded for strong client ownership, successful deployment of data-driven models, and leading post-deployment value realization discussions with refinery stakeholders.

3. Rising Star Award: Recognized as a top performer within the first year of joining, based on technical contribution, execution quality, and stakeholder impact.

4. Leadership Milestone: Led and managed an 8-member cross-functional team (process engineers and data scientists), owning end-to-end delivery of real-time monitoring, optimization dashboards, and predictive models for a global petrochemical client (SABIC).

5. High-Impact Industrial Deployment: Played a key role in deploying real-time optimization, soft-sensor, and forecasting models into live production environments across petrochemical and metals processing plants, moving solutions from prototype to sustained operations.

6. International Publication & Presentation: Published and presented research at an international conference organized by the International Committee for Study of Bauxite, Alumina & Aluminium (ICSOBA), contributing applied research in the alumina and aluminum domain.

7. Cross-Geo Technical Collaboration: Contributed to 14A node Dry Etch development at Intel through close collaboration with US-based focus teams, supporting advanced process control model development and recipe standardization efforts.

Education
  • MBA (Pursuing), Indian Institute of Management Ahmedabad. 2024-2026
  • M.E. in Chemical Engineering, Birla Institute of Technology and Science, Pilani, 2019
  • B.Tech in Chemical Engineering, Jawaharlal Nehru Technological University, Hyderabad, 2016
Certification
  • Training on Data Science from Mathworks, 2019,
     
  • Trained in statistics and Six Sigma, 2025.
Extra-curricular
  • Academic Representative for the BPGP batch at IIM Ahmedabad. Placement Coordinator at BITS Pilani, 2018-19. Vice-president of the National Level Technical Fest in 2015.